Process Engineer

Merck•Dallas, TX

19h•Onsite

About The Position

The Process Engineer provides day-to-day technical support for blending and chemical manufacturing operations producing CMP slurries and Surface Prep & Cleans (SP&C) products for Tier 1 semiconductor foundries at the Dallas facility. This role executes hands-on troubleshooting, data analysis, and documentation work that supports process reliability, product quality, and continuous improvement objectives, while working closely with Production, Quality, Supply Chain, and Maintenance teams. The position requires regular presence on the manufacturing floor, direct use of process data systems (SAP, LIMS, SCADA/DCS historian trends), and application of structured problem-solving and statistical tools to support operators, monitor process performance, and drive operational excellence in a high-purity, low-variability manufacturing environment with change control.

Requirements

Bachelor’s degree in chemical engineering, Industrial Engineering, or a similar engineering discipline.
2+ years of manufacturing or process engineering experience, ideally in batch chemical, specialty chemical, or semiconductor materials manufacturing.
Proficiency in Microsoft Office applications, AutoCAD and Python.
Effective communication and interpersonal skills for cross-functional collaboration with Production, Quality, Maintenance, and Supply Chain.
Ability to work effectively in a cross-functional manufacturing environment and adapt to shifting production priorities.

Nice To Haves

Experience in chemical manufacturing, specialty chemicals, semiconductor materials, or related regulated industries.
Experience in FEED projects with involvement in qualification and validation using DOEs.
Strong analytical and problem-solving skills, including comfort with basic statistical concepts (mean/variance, control limits, Cpk/Ppk).
Ability to analyze process and quality data and develop practical, data-driven solutions.
Familiarity with statistical analysis and process improvement tools such as Palantir Foundry, JMP, Minitab, or Python (pandas/numpy) for SPC and trend analysis.
Experience with SAP or other ERP systems, including BOM, routing, and production order transactions.
Knowledge of Process Safety Management, Lean Manufacturing principles and/or Six Sigma methodology (Green Belt training or certification a plus).
Exposure to quality systems, deviation investigations, and CAPA processes within an eQMS environment.
Experience supporting manufacturing operations in a regulated environment (ISO 9001/14001/45001, GMP-aligned, or semiconductor-industry quality systems).
Familiarity with automation/control systems (e.g., Rockwell/Allen-Bradley, FactoryTalk, SCADA/DCS historians) for reviewing process trend data.
Hands on PLC coding experience is a plus.
Ability to analyze process and quality data and develop practical, data-driven solutions.

Responsibilities

Provide daily process engineering support to blending and manufacturing operations, including real-time review of batch records, recipe parameters, and SCADA/DCS process trends (e.g., Rockwell/Allen-Bradley, FactoryTalk, or equivalent control systems).
Support operators and production supervisors in resolving process-related issues affecting blending assets, filtration/purification skids, and UPW systems using process flow diagrams (PFDs), P&IDs, and standard operating procedures (SOPs).
Develop and monitor process performance dashboards against control limits and operating envelopes; identify opportunities to improve efficiency, quality, and throughput using multivariate SPC charts and OEE metrics.
Participate in daily tier meetings and production meetings; communicate process-related performance and investigation updates using visual management boards and shift handover reports.
Conduct troubleshooting activities for process deviations, equipment issues, and manufacturing concerns using first-principles chemical engineering (mass/energy balances, reaction and mixing fundamentals) and structured methodologies (5-Why, Fishbone/Ishikawa, A3).
Support root cause analysis efforts, applying statistical process control (SPC) and basic multivariate analysis techniques (e.g., Pareto analysis, control charts, Cpk/Ppk calculations) using tools such as JMP, Minitab, or Python.
Assist with deviation investigations, 8Ds, and corrective and preventive actions (CAPA) within the site's electronic quality management system (eQMS/QMS).
Collaborate with Quality, Operations, and Maintenance teams to implement corrective actions and verify effectiveness.
Identify opportunities for waste reduction, yield improvement, cycle time reduction, and process optimization using Lean Manufacturing tools (value stream mapping, 5S, standard work).
Support implementation of Lean Manufacturing and Six Sigma continuous improvement initiatives (DMAIC framework); Green Belt certification or working toward certification is a plus.
Participate in Kaizen events and operational excellence projects, quantifying and communicating the business impact of improvements.
Monitor effectiveness of implemented improvements using statistical trending and communicate results to the site leadership.
Create and revise manufacturing procedures, work instructions, batch records, and process and data maps in accordance with GMP-aligned document control practices.
Support change control activities and document revisions within the site's change management system.
Maintain process engineering records, drawings, technical files, P&IDs and process specification sheets defining operating parameters and control limits.
Assist with development and maintenance of process specifications, recipe management, and operating parameter documentation.
Support SAP-related manufacturing data updates, including bill of materials (BOM) and routing reviews, production order execution, and batch record reconciliation as assigned.
Support execution of engineering trials, engineering batches, and product transfer activities for CMP slurry and SP&C formulations.
Collect and analyze process data during validation, qualification (IQ/OQ/PQ), and process capability studies.
Assist senior engineers with manufacturing readiness assessments and process qualification activities for new product introduction (NPI) and technology transfer projects.
Participate in new product introduction and commercialization projects, including scale-up from lab/pilot to full production scale.
Work with Maintenance and Operations teams to troubleshoot equipment-related process issues on blending tanks, filtration/purification skids, pumps, and instrumentation.
Assist with equipment qualification, commissioning, and startup activities, including review of control system logic and instrumentation calibration records.
Support process improvements related to equipment performance and reliability, using CMMS (computerized maintenance management system) data to identify recurring failure modes.
Participate in preventive maintenance reviews and process optimization initiatives in coordination with Automation and Reliability engineering.
Assist with internal and external audit preparation activities for ISO 9001, ISO 14001, and ISO 45001 certified manufacturing systems.
Ensure process documentation remains current and compliant with quality system and change control requirements.
Support CAPA implementation and effectiveness checks within the site's eQMS.
Participate in risk assessments (e.g., FMEA, PHA/HAZOP) and process safety initiatives.
Develop expertise in CMP and SP&C processes.
Gain hands-on experience supporting daily production, troubleshooting process issues on the manufacturing floor, and understanding how engineering decisions impact safety, quality, delivery, and cost.
Lead projects from design to execution and sustaining phases.
Work closely with Production, Quality, Supply Chain, Maintenance, and R&D teams, gaining exposure to the broader manufacturing value chain and developing skills needed for future technical and leadership roles.
Learn digital tools to integrate in production data analytics and automation processes driving the site towards industry 4.0.
Exposure to customer relationship management, and audit programs.